Index: firmware/App/Controllers/Heaters.c =================================================================== diff -u -r72ba5f3c63325b00306b544b2513c03500919d06 -r6499ea25921fcf67826fa0c35bb03caf411ba542 --- firmware/App/Controllers/Heaters.c (.../Heaters.c) (revision 72ba5f3c63325b00306b544b2513c03500919d06) +++ firmware/App/Controllers/Heaters.c (.../Heaters.c) (revision 6499ea25921fcf67826fa0c35bb03caf411ba542) @@ -1,14 +1,14 @@ /************************************************************************** * -* Copyright (c) 2020-2022 Diality Inc. - All Rights Reserved. +* Copyright (c) 2020-2023 Diality Inc. - All Rights Reserved. * * THIS CODE MAY NOT BE COPIED OR REPRODUCED IN ANY FORM, IN PART OR IN * WHOLE, WITHOUT THE EXPLICIT PERMISSION OF THE COPYRIGHT OWNER. * * @file Heaters.c * -* @author (last) Bill Bracken -* @date (last) 22-Aug-2022 +* @author (last) Dara Navaei +* @date (last) 02-Dec-2022 * * @author (original) Dara Navaei * @date (original) 23-Apr-2020 @@ -23,6 +23,7 @@ #include "AlarmMgmt.h" #include "DGDefs.h" #include "FlowSensors.h" +#include "FPGA.h" #include "Heaters.h" #include "MessageSupport.h" #include "ModeFill.h" @@ -37,6 +38,7 @@ #include "TaskPriority.h" #include "TemperatureSensors.h" #include "Timers.h" +#include "Utilities.h" #include "Voltages.h" /** @@ -48,7 +50,8 @@ #define HEATERS_MAX_DUTY_CYCLE 1.00F ///< Heaters max duty cycle (100%). #define HEATERS_MIN_DUTY_CYCLE 0.00F ///< Heaters minimum duty cycle (0.00%). -#define HEATERS_MIN_HEAT_DISINFECT_DUTY_CYCLE 0.6F ///< Heaters minimum duty cycle during heat disinfect. +#define HEATERS_DISINFECT_DUTY_CYCLE 0.80F ///< Heaters disinfect cycle. +#define HEATERS_DISINFECT_TEMPERATURE_DRIFT_C 3.0F ///< Heaters disinfect temperature drift in C. #define HEATERS_MIN_EST_GAIN 0.2F ///< Heaters minimum estimation gain. #define HEATERS_MAX_EST_GAIN 5.0F ///< Heaters maximum estimation gain. #define HEATERS_NEUTRAL_EST_GAIN 1.0F ///< Heaters neutral estimation gain. @@ -63,13 +66,15 @@ #define HEATERS_VOLTAGE_OUT_OF_RANGE_TIMEOUT_MS ( 2 * MS_PER_SECOND ) ///< Heaters voltage out of range time out in milliseconds. #define HEATERS_MAX_VOLTAGE_OUT_OF_RANGE_TOL 0.2F ///< Heaters max voltage out of range tolerance. #define TRIMMER_HEATER_MAX_POWER_W 66.5F ///< Trimmer heater maximum power in Watts. -#define TRIMMER_HEATER_CONTROL_CHECK_INTERVAL_COUNT ( ( 30 * MS_PER_SECOND ) / TASK_GENERAL_INTERVAL ) ///< Trimmer heater control interval count. +#define TRIMMER_HEATER_INITIAL_CONTROL_INTERVAL_COUNT ( ( 10 * MS_PER_SECOND ) / TASK_GENERAL_INTERVAL ) ///< Trimmer heater initial control interval count. +#define TRIMMER_HEATER_CONTROL_INTERVAL_COUNT ( ( 30 * MS_PER_SECOND ) / TASK_GENERAL_INTERVAL ) ///< Trimmer heater control interval count. #define DELTA_TEMPERATURE_TIME_COSNTANT_C 8.6F ///< Delta temperature calculated from time constant. #define PRIMARY_HEATER_DUTY_CYCLE_PER_TEMPERATURE_C 0.015F ///< Primary heaters duty cycle per temperature in C. #define DATA_PUBLISH_COUNTER_START_COUNT 70 ///< Data publish counter start count. #define MIN_RO_HEATER_FLOWRATE_LPM 0.2F ///< Minimum target RO heater flow rate in L/min. #define PRIMARY_HEATER_POWER_TOL 0.1F ///< Primary heater power tolerance. +#define MAIN_PIMARY_HEATER_VOLTAGE_ADC_FPGA_ERROR_TIMEOUT_MS ( 2 * MS_PER_SECOND ) ///< Main primary heater voltage ADC FPGA error. static const F32 WATER_SPECIFIC_HEAT_DIVIDED_BY_MINUTES = 4184 / SEC_PER_MIN; ///< Water specific heat in J/KgC / 60. static const F32 PRIMARY_HEATERS_MAXIMUM_POWER_WATTS = 475 + 237.5F; ///< Primary heaters maximum power (main primary = 475W and small primary = 237.5W). @@ -87,14 +92,15 @@ F32 targetFlow; ///< Heater target flow. BOOL hasTargetTempChanged; ///< Heater target temperature change flag indicator. F32 heaterEstGain; ///< Heater estimation gain during the run. - BOOL hasTargetBeenReached; ///< Heater flag to indicate whether the target temperature has been reached. F32 calculatedTemperature; ///< Heater calculated temperature. DG_RESERVOIR_ID_T inactiveRsrvr; ///< Heater inactive reservoir. + U32 controlIntervalCounter; ///< Heater control interval counter. + BOOL isThisFirstControl; ///< Heater is this first control interval. + BOOL useLastDutyCycle; ///< Heater has use previous duty cycle been requested flag. } HEATER_STATUS_T; static HEATER_STATUS_T heatersStatus[ NUM_OF_DG_HEATERS ]; ///< Heaters status. static U32 dataPublicationTimerCounter; ///< Data publication timer counter. -static U32 trimmerHeaterControlCounter; ///< Trimmer heater control counter. static OVERRIDE_U32_T heatersDataPublishInterval = { HEATERS_DATA_PUBLISH_INTERVAL, HEATERS_DATA_PUBLISH_INTERVAL, 0, 0 }; ///< Heaters data publish time interval. // ********** private function prototypes ********** @@ -121,28 +127,28 @@ * @brief * The initHeaters initializes the heaters driver. * @details Inputs: none - * @details Outputs: voltageMonitorTimeCounter, heaterStatus, - * hasTreatmentInternalTempBeenSet, dataPublicationTimerCounter, - * trimmerHeaterControlCounter + * @details Outputs: heaterStatus, + * dataPublicationTimerCounter * @return none *************************************************************************/ void initHeaters( void ) { DG_HEATERS_T heater; dataPublicationTimerCounter = DATA_PUBLISH_COUNTER_START_COUNT; - trimmerHeaterControlCounter = 0; for ( heater = DG_PRIMARY_HEATER; heater < NUM_OF_DG_HEATERS; heater++ ) { - heatersStatus[ heater ].targetTemp = 0.0; - heatersStatus[ heater ].state = HEATER_EXEC_STATE_OFF; - heatersStatus[ heater ].startHeaterSignal = FALSE; - heatersStatus[ heater ].isHeaterOn = FALSE; - heatersStatus[ heater ].dutyCycle = 0.0; - heatersStatus[ heater ].targetFlow = 0.0; - heatersStatus[ heater ].hasTargetTempChanged = FALSE; - heatersStatus[ heater ].heaterEstGain = HEATERS_NEUTRAL_EST_GAIN; - heatersStatus[ heater ].hasTargetBeenReached = FALSE; + heatersStatus[ heater ].targetTemp = 0.0F; + heatersStatus[ heater ].state = HEATER_EXEC_STATE_OFF; + heatersStatus[ heater ].startHeaterSignal = FALSE; + heatersStatus[ heater ].isHeaterOn = FALSE; + heatersStatus[ heater ].dutyCycle = 0.0F; + heatersStatus[ heater ].targetFlow = 0.0F; + heatersStatus[ heater ].hasTargetTempChanged = FALSE; + heatersStatus[ heater ].heaterEstGain = HEATERS_NEUTRAL_EST_GAIN; + heatersStatus[ heater ].controlIntervalCounter = 0; + heatersStatus[ heater ].isThisFirstControl = TRUE; + heatersStatus[ heater ].useLastDutyCycle = FALSE; } // Initialize the persistent alarms @@ -152,6 +158,10 @@ initPersistentAlarm( ALARM_ID_DG_PRIMARY_HEATER_POWER_VOLTAGE_OUT_OF_RANGE, HEATERS_VOLTAGE_OUT_OF_RANGE_TIMEOUT_MS, HEATERS_VOLTAGE_OUT_OF_RANGE_TIMEOUT_MS ); initPersistentAlarm( ALARM_ID_RO_FLOW_TOO_LOW_WHILE_PRIMARY_HEATER_IS_ON, HEATERS_ON_NO_FLOW_TIMEOUT_MS, HEATERS_ON_NO_FLOW_TIMEOUT_MS ); initPersistentAlarm( ALARM_ID_DIALYSATE_FLOW_TOO_LOW_WHILE_TRIMMER_HEATER_IS_ON, HEATERS_ON_NO_FLOW_TIMEOUT_MS, HEATERS_ON_NO_FLOW_TIMEOUT_MS ); + + // Initialize the FPGA persistent alarm + initFPGAPersistentAlarm( FPGA_PERS_ERROR_MAIN_PRIMARY_HEATER_VOLTAGE_ADC, ALARM_ID_DG_MAIN_PRIMARY_HEATER_FPGA_FAULT, + MAIN_PIMARY_HEATER_VOLTAGE_ADC_FPGA_ERROR_TIMEOUT_MS, MAIN_PIMARY_HEATER_VOLTAGE_ADC_FPGA_ERROR_TIMEOUT_MS ); } /*********************************************************************//** @@ -217,9 +227,17 @@ { if ( HEATER_EXEC_STATE_OFF == heatersStatus[ heater ].state ) { - status = TRUE; heatersStatus[ heater ].startHeaterSignal = TRUE; + status = TRUE; } + +#ifndef _RELEASE_ + if ( ( SW_CONFIG_ENABLE_VALUE == getSoftwareConfigStatus( SW_CONFIG_DISABLE_TRIMMER_HEATER ) ) && ( DG_TRIMMER_HEATER == heater ) ) + { + heatersStatus[ heater ].startHeaterSignal = FALSE; + status = FALSE; + } +#endif } else { @@ -321,31 +339,37 @@ if ( TRUE == heatersStatus[ heater ].isHeaterOn ) { ALARM_ID_T alarm; - F32 measFlow; - F32 minFlow; - BOOL isFlowLow; + F32 measFlow = 0.0F; + F32 minFlow = 0.0F; + BOOL isFlowLow = FALSE; if ( DG_PRIMARY_HEATER == heater ) { - alarm = ALARM_ID_RO_FLOW_TOO_LOW_WHILE_PRIMARY_HEATER_IS_ON; - measFlow = getMeasuredFlowRateLPM( RO_FLOW_SENSOR ); - minFlow = MIN_RO_FLOWRATE_LPM; + alarm = ALARM_ID_RO_FLOW_TOO_LOW_WHILE_PRIMARY_HEATER_IS_ON; + measFlow = getMeasuredFlowRateLPM( RO_FLOW_SENSOR ); + minFlow = MIN_RO_HEATER_FLOWRATE_LPM; + isFlowLow = ( measFlow < minFlow ? TRUE : FALSE ); } else { - alarm = ALARM_ID_DIALYSATE_FLOW_TOO_LOW_WHILE_TRIMMER_HEATER_IS_ON; - measFlow = getMeasuredFlowRateLPM( DIALYSATE_FLOW_SENSOR ); - minFlow = MIN_DIALYSATE_FLOWRATE_LPM; + alarm = ALARM_ID_DIALYSATE_FLOW_TOO_LOW_WHILE_TRIMMER_HEATER_IS_ON; + measFlow = getMeasuredRawFlowRateLPM( DIALYSATE_FLOW_SENSOR ); + minFlow = MIN_DIALYSATE_FLOWRATE_LPM; + isFlowLow = ( measFlow > minFlow ? FALSE : TRUE ); } - isFlowLow = ( measFlow < minFlow ? TRUE : FALSE ); - checkPersistentAlarm( alarm, isFlowLow, measFlow, minFlow ); } else { - checkPersistentAlarm( ALARM_ID_RO_FLOW_TOO_LOW_WHILE_PRIMARY_HEATER_IS_ON, FALSE, 0.0, 0.0 ); - checkPersistentAlarm( ALARM_ID_DIALYSATE_FLOW_TOO_LOW_WHILE_TRIMMER_HEATER_IS_ON, FALSE, 0.0, 0.0 ); + if ( DG_PRIMARY_HEATER == heater ) + { + checkPersistentAlarm( ALARM_ID_RO_FLOW_TOO_LOW_WHILE_PRIMARY_HEATER_IS_ON, FALSE, 0.0F, 0.0F ); + } + else + { + checkPersistentAlarm( ALARM_ID_DIALYSATE_FLOW_TOO_LOW_WHILE_TRIMMER_HEATER_IS_ON, FALSE, 0.0F, 0.0F ); + } } } @@ -417,6 +441,20 @@ /*********************************************************************//** * @brief + * The setTrimmerHeaterUseLastDutyCycleStatus function sets the flag that + * signals the trimmer heater control to use the last duty cycle or not + * @details Inputs: none + * @details Outputs: heatersStatus + * @param status which is the flag to indicate the status + * @return none + *************************************************************************/ +void setTrimmerHeaterUseLastDutyCycleStatus( BOOL status ) +{ + heatersStatus[ DG_TRIMMER_HEATER ].useLastDutyCycle = status; +} + +/*********************************************************************//** + * @brief * The handleHeaterStateOff function handles the heater not running state. * @details Inputs: heaterStatus * @details Outputs: heaterStatus @@ -433,7 +471,7 @@ heatersStatus[ heater ].startHeaterSignal = FALSE; // Depending on which heater is called, go to different states - state = ( heater == DG_PRIMARY_HEATER ? HEATER_EXEC_STATE_PRIMARY_RAMP_TO_TARGET : HEATER_EXEC_STATE_TRIMMER_RAMP_TO_TARGET ); + state = ( DG_PRIMARY_HEATER == heater ? HEATER_EXEC_STATE_PRIMARY_RAMP_TO_TARGET : HEATER_EXEC_STATE_TRIMMER_RAMP_TO_TARGET ); } return state; @@ -452,8 +490,8 @@ HEATERS_STATE_T state = HEATER_EXEC_STATE_PRIMARY_RAMP_TO_TARGET; DG_HEATERS_T heater = DG_PRIMARY_HEATER; F32 inletTemperature = getTemperatureValue( (U32)TEMPSENSORS_HEAT_DISINFECT ); - F32 targetFlow = 0.0; - F32 dutyCycle = 0.0; + F32 targetFlow = 0.0F; + F32 dutyCycle = 0.0F; F32 targetTemperature = heatersStatus[ heater ].targetTemp; DG_OP_MODE_T opMode = getCurrentOperationMode(); @@ -481,11 +519,16 @@ } else { - // Do nothing the mode that DG is in right now, does not need heaters to be on + // Calculate the energy equation and set the duty cycle + // This is for other modes (i.e. standby or service) + targetFlow = getTargetROPumpFlowRateLPM(); + dutyCycle = calculatePrimaryHeaterDutyCycle( targetTemperature, inletTemperature, targetFlow, FALSE ); + state = HEATER_EXEC_STATE_PRIMARY_CONTROL_TO_TARGET; } - // Update the calculated target temperature + // Update the calculated target temperature and flow heatersStatus[ DG_PRIMARY_HEATER ].calculatedTemperature = targetTemperature; + heatersStatus[ DG_PRIMARY_HEATER ].targetFlow = targetFlow; setHeaterDutyCycle( heater, dutyCycle ); return state; @@ -508,7 +551,20 @@ { state = HEATER_EXEC_STATE_PRIMARY_RAMP_TO_TARGET; } + else if ( TRUE == heatersStatus[ heater ].hasTargetTempChanged ) + { + F32 inletTemperature = getTemperatureValue( (U32)TEMPSENSORS_HEAT_DISINFECT ); + F32 targetTemperature = heatersStatus[ heater ].targetTemp; + F32 targetFlow = getTargetROPumpFlowRateLPM(); + F32 dutyCycle = calculatePrimaryHeaterDutyCycle( targetTemperature, inletTemperature, targetFlow, TRUE ); + heatersStatus[ heater ].calculatedTemperature = targetTemperature; + heatersStatus[ heater ].targetFlow = targetFlow; + heatersStatus[ heater ].hasTargetTempChanged = FALSE; + + setHeaterDutyCycle( heater, dutyCycle ); + } + return state; } @@ -524,32 +580,24 @@ *************************************************************************/ static HEATERS_STATE_T handleHeaterStateControlToDisinfectTarget( DG_HEATERS_T heater ) { - HEATERS_STATE_T state = HEATER_EXEC_STATE_CONTROL_TO_DISINFECT_TARGET; + HEATERS_STATE_T state = HEATER_EXEC_STATE_CONTROL_TO_DISINFECT_TARGET; + F32 currentTemperature = getTemperatureValue( TEMPSENSORS_HEAT_DISINFECT ); + F32 targetTemperature = heatersStatus[ DG_PRIMARY_HEATER ].targetTemp; - F32 heatDisinfectSensorTemp = getTemperatureValue( TEMPSENSORS_HEAT_DISINFECT ); - - // Check if the heaters control conditions have changed, if yes, switch back to ramp to target - if ( TRUE == haveHeaterControlConditionsChanged( heater ) ) + if ( currentTemperature < targetTemperature ) { - state = HEATER_EXEC_STATE_PRIMARY_RAMP_TO_TARGET; + setHeaterDutyCycle( DG_TRIMMER_HEATER, HEATERS_MAX_DUTY_CYCLE ); + setHeaterDutyCycle( DG_PRIMARY_HEATER, HEATERS_MAX_DUTY_CYCLE ); } - - // If the heat disinfect sensor indicates that the temperature is below target temperature but the target temperature had been reached - // before turn on the heaters with 100% power - if ( ( heatDisinfectSensorTemp <= heatersStatus[ heater ].targetTemp ) && ( TRUE == heatersStatus[ heater ].hasTargetBeenReached ) ) + else if ( currentTemperature - targetTemperature < HEATERS_DISINFECT_TEMPERATURE_DRIFT_C ) { - heatersStatus[ heater ].hasTargetBeenReached = FALSE; - setHeaterDutyCycle( heater, HEATERS_MAX_DUTY_CYCLE ); + setHeaterDutyCycle( DG_TRIMMER_HEATER, HEATERS_DISINFECT_DUTY_CYCLE ); + setHeaterDutyCycle( DG_PRIMARY_HEATER, HEATERS_DISINFECT_DUTY_CYCLE ); } - - // If we have reached to target temperature, turn off the heaters - if ( heatDisinfectSensorTemp > heatersStatus[ heater ].targetTemp ) + else { - // Set the flag to true for the next run - heatersStatus[ heater ].hasTargetBeenReached = TRUE; - // The primary heater are not turned off but it is set to a minimum duty cycle so the temperature is kept - // above the target - setHeaterDutyCycle( heater, HEATERS_MIN_HEAT_DISINFECT_DUTY_CYCLE ); + setHeaterDutyCycle( DG_TRIMMER_HEATER, HEATERS_MIN_DUTY_CYCLE ); + setHeaterDutyCycle( DG_PRIMARY_HEATER, HEATERS_MIN_DUTY_CYCLE ); } return state; @@ -567,17 +615,25 @@ { HEATERS_STATE_T state = HEATER_EXEC_STATE_TRIMMER_RAMP_TO_TARGET; DG_HEATERS_T heater = DG_TRIMMER_HEATER; - F32 currentTemperature = 0.0; + F32 currentTemperature = 0.0F; F32 targetFlowLPM = getTargetDialysateFlowLPM(); - F32 dutyCycle = 0.0; + F32 dutyCycle = 0.0F; F32 targetTemperature = heatersStatus[ heater ].targetTemp; DG_OP_MODE_T opMode = getCurrentOperationMode(); if ( ( DG_MODE_FILL == opMode ) || ( DG_MODE_GENE == opMode ) || ( DG_MODE_DRAI == opMode ) ) { - currentTemperature = getReservoirCurrentTemperature(); - dutyCycle = calculateTrimmerHeaterDutyCycle( targetTemperature, currentTemperature, targetFlowLPM, TRUE ); - state = HEATER_EXEC_STATE_TRIMMER_CONTROL_TO_TARGET; + if ( FALSE == heatersStatus[ heater ].useLastDutyCycle ) + { + currentTemperature = getReservoirCurrentTemperature(); + dutyCycle = calculateTrimmerHeaterDutyCycle( targetTemperature, currentTemperature, targetFlowLPM, TRUE ); + } + else + { + dutyCycle = heatersStatus[ heater ].dutyCycle; + } + + state = HEATER_EXEC_STATE_TRIMMER_CONTROL_TO_TARGET; } else if ( DG_MODE_HEAT == opMode ) { @@ -589,13 +645,20 @@ dutyCycle = calculateTrimmerHeaterDutyCycle( targetTemperature, currentTemperature, targetFlowLPM, FALSE ); state = HEATER_EXEC_STATE_CONTROL_TO_DISINFECT_TARGET; } + else + { + // If not any of the above modes, just calculate the energy equation based on TRo + currentTemperature = getTemperatureValue( (U32)TEMPSENSORS_OUTLET_REDUNDANT ); + dutyCycle = calculateTrimmerHeaterDutyCycle( targetTemperature, currentTemperature, targetFlowLPM, TRUE ); + state = HEATER_EXEC_STATE_TRIMMER_CONTROL_TO_TARGET; + } // Update the calculated target temperature // Reset the duty cycle since the reservoir has been switched heatersStatus[ heater ].calculatedTemperature = currentTemperature; heatersStatus[ heater ].inactiveRsrvr = getInactiveReservoir(); heatersStatus[ heater ].targetFlow = targetFlowLPM; - trimmerHeaterControlCounter = 0; + heatersStatus[ heater ].isThisFirstControl = TRUE; // Cap the minimum duty cycle. So if it is calculated to negative, set it to 0 dutyCycle = MAX( dutyCycle, HEATERS_MIN_DUTY_CYCLE ); @@ -615,29 +678,35 @@ static HEATERS_STATE_T handleHeaterStateTrimmerControlToTarget( void ) { HEATERS_STATE_T state = HEATER_EXEC_STATE_TRIMMER_CONTROL_TO_TARGET; - F32 tempDutyCycle = 0.0; + F32 tempDutyCycle = 0.0F; + DG_HEATERS_T heater = DG_TRIMMER_HEATER; + U32 controlInterval = ( TRUE == heatersStatus[ heater ].isThisFirstControl ? TRIMMER_HEATER_INITIAL_CONTROL_INTERVAL_COUNT : + TRIMMER_HEATER_CONTROL_INTERVAL_COUNT ); // If the inactive reservoir has changed from the last run transition to ramp state to recalculate the // duty cycle for the next delivery - if ( heatersStatus[ DG_TRIMMER_HEATER ].inactiveRsrvr != getInactiveReservoir() ) + if ( heatersStatus[ heater ].inactiveRsrvr != getInactiveReservoir() ) { state = HEATER_EXEC_STATE_TRIMMER_RAMP_TO_TARGET; } - else if ( ++trimmerHeaterControlCounter > TRIMMER_HEATER_CONTROL_CHECK_INTERVAL_COUNT ) + else if ( ++heatersStatus[ heater ].controlIntervalCounter > controlInterval ) { + // Reset the control counter + heatersStatus[ heater ].controlIntervalCounter = 0; + heatersStatus[ heater ].isThisFirstControl = FALSE; + // When the trimmer heater is on, its duty cycle is adjusted at the control interval. For this control check, // dialysate inlet temperature sensor is used rather than the theoretical calculations. F32 outletRedundantTemperature = getTemperatureValue( TEMPSENSORS_OUTLET_REDUNDANT ); - F32 targetTemperature = heatersStatus[ DG_TRIMMER_HEATER ].targetTemp; - F32 targetFlowLPM = heatersStatus[ DG_TRIMMER_HEATER ].targetFlow; + F32 targetTemperature = heatersStatus[ heater ].targetTemp; + F32 targetFlowLPM = heatersStatus[ heater ].targetFlow; F32 dutyCycle = calculateTrimmerHeaterDutyCycle( targetTemperature, outletRedundantTemperature, targetFlowLPM, TRUE ); - trimmerHeaterControlCounter = 0; - tempDutyCycle = heatersStatus[ DG_TRIMMER_HEATER ].dutyCycle + dutyCycle; + tempDutyCycle = heatersStatus[ heater ].dutyCycle + dutyCycle; tempDutyCycle = MIN( tempDutyCycle, HEATERS_MAX_DUTY_CYCLE ); tempDutyCycle = MAX( tempDutyCycle, HEATERS_MIN_DUTY_CYCLE ); - setHeaterDutyCycle( DG_TRIMMER_HEATER, tempDutyCycle ); + setHeaterDutyCycle( heater, tempDutyCycle ); } return state; @@ -654,17 +723,24 @@ *************************************************************************/ static void setHeaterDutyCycle( DG_HEATERS_T heater, F32 pwm ) { - if ( DG_PRIMARY_HEATER == heater ) + if ( heater < NUM_OF_DG_HEATERS ) { - setMainPrimaryHeaterPWM( pwm ); - setSmallPrimaryHeaterPWM( pwm ); + if ( DG_PRIMARY_HEATER == heater ) + { + setMainPrimaryHeaterPWM( pwm ); + setSmallPrimaryHeaterPWM( pwm ); + } + else if ( DG_TRIMMER_HEATER == heater ) + { + setTrimmerHeaterPWM( pwm ); + } + + heatersStatus[ heater ].dutyCycle = pwm; } - else if ( DG_TRIMMER_HEATER == heater ) + else { - setTrimmerHeaterPWM( pwm ); + SET_ALARM_WITH_2_U32_DATA( ALARM_ID_DG_SOFTWARE_FAULT, SW_FAULT_ID_HEATERS_INVALID_HEATER_ID_SELECTED, heater ); } - - heatersStatus[ heater ].dutyCycle = pwm; } /*********************************************************************//** @@ -707,7 +783,7 @@ { // Get the primary heater's efficiency and the last fill temperature from the ModeFill F32 heaterEstGain = heatersStatus[ DG_TRIMMER_HEATER ].heaterEstGain; - F32 dutyCycle = 0.0; + F32 dutyCycle = 0.0F; #ifndef _RELEASE_ if ( getSoftwareConfigStatus( SW_CONFIG_DISABLE_HEATERS_EFFICIENCY ) != SW_CONFIG_ENABLE_VALUE ) @@ -744,11 +820,10 @@ BOOL hasFlowChanged = ( fabs( targetFlow - heatersStatus[ heater ].targetFlow ) > NEARLY_ZERO ? TRUE : FALSE ); // Check if the target flow has changed or the target temperature has changed. - if ( ( TRUE == hasFlowChanged ) || ( TRUE == heatersStatus[ heater ].hasTargetTempChanged ) ) + if ( TRUE == hasFlowChanged ) { - status = TRUE; - heatersStatus[ heater ].targetFlow = targetFlow; - heatersStatus[ heater ].hasTargetTempChanged = FALSE; + status = TRUE; + heatersStatus[ heater ].targetFlow = targetFlow; } return status; @@ -831,18 +906,19 @@ { HEATERS_DATA_T data; - data.mainPrimayHeaterDC = heatersStatus[ DG_PRIMARY_HEATER ].dutyCycle * 100.0; // The duty cycle of the primary heater is divided into 2 parts and is applied to main // and small primary heaters. So they are always the same. - data.smallPrimaryHeaterDC = heatersStatus[ DG_PRIMARY_HEATER ].dutyCycle * 100.0; - data.trimmerHeaterDC = heatersStatus[ DG_TRIMMER_HEATER ].dutyCycle * 100.0; + data.mainPrimayHeaterDC = heatersStatus[ DG_PRIMARY_HEATER ].dutyCycle * FRACTION_TO_PERCENT_FACTOR; + data.smallPrimaryHeaterDC = heatersStatus[ DG_PRIMARY_HEATER ].dutyCycle * FRACTION_TO_PERCENT_FACTOR; + data.trimmerHeaterDC = heatersStatus[ DG_TRIMMER_HEATER ].dutyCycle * FRACTION_TO_PERCENT_FACTOR; data.primaryTargetTemp = heatersStatus[ DG_PRIMARY_HEATER ].targetTemp; data.trimmerTargetTemp = heatersStatus[ DG_TRIMMER_HEATER ].targetTemp; data.primaryHeaterState = heatersStatus[ DG_PRIMARY_HEATER ].state; data.trimmerHeaterState = heatersStatus[ DG_TRIMMER_HEATER ].state; - data.primaryEfficiency = heatersStatus[ DG_PRIMARY_HEATER ].heaterEstGain * 100; + data.primaryEfficiency = heatersStatus[ DG_PRIMARY_HEATER ].heaterEstGain * FRACTION_TO_PERCENT_FACTOR; data.primaryCalcTargetTemp = heatersStatus[ DG_PRIMARY_HEATER ].calculatedTemperature; data.trimmerCalcCurrentTemp = heatersStatus[ DG_TRIMMER_HEATER ].calculatedTemperature; + data.trimmerUseLastDC = (U32)heatersStatus[ DG_TRIMMER_HEATER ].useLastDutyCycle; dataPublicationTimerCounter = 0; broadcastData( MSG_ID_DG_HEATERS_DATA, COMM_BUFFER_OUT_CAN_DG_BROADCAST, (U08*)&data, sizeof( HEATERS_DATA_T ) ); @@ -852,22 +928,13 @@ /*********************************************************************//** * @brief * The monitorHeatersVoltage function monitors the heaters' voltages - * @details Inputs: voltageMonitorTimeCounter - * @details Outputs: voltageMonitorTimeCounter + * @details Inputs: none + * @details Outputs: none * @return none *************************************************************************/ static void monitorHeatersVoltage( void ) { - F32 mainPriVoltage = getMonitoredLineLevel( MONITORED_LINE_24V_GND_MAIN_PRIM_HTR_V ); - -#ifndef _RELEASE_ - if ( SW_CONFIG_ENABLE_VALUE == getSoftwareConfigStatus( SW_CONFIG_ENABLE_V3_SYSTEM ) ) - { - // V3 use CPU based value for Primary, same as Secondary - mainPriVoltage = getMonitoredLineLevel( MONITORED_LINE_24V_GND_SMALL_PRIM_HTR_V ); - } -#endif - + F32 mainPriVoltage = getMonitoredLineLevel( MONITORED_LINE_24V_GND_MAIN_PRIM_HTR_V ); F32 smallPriVoltage = getMonitoredLineLevel( MONITORED_LINE_24V_GND_SMALL_PRIM_HTR_V ); F32 trimmerVoltage = getMonitoredLineLevel( MONITORED_LINE_24V_GND_TRIM_HTR_V ); @@ -876,22 +943,41 @@ F32 smallPriDC = heatersStatus[ DG_PRIMARY_HEATER ].dutyCycle; F32 trimmerDC = heatersStatus[ DG_TRIMMER_HEATER ].dutyCycle; + // The expected voltage is the inverse of the duty cycle F32 mainPriExpectedVoltage = HEATERS_MAX_OPERATING_VOLTAGE_V * ( 1.0F - mainPriDC ); F32 smallPriExpectedVoltage = HEATERS_MAX_OPERATING_VOLTAGE_V * ( 1.0F - smallPriDC ); F32 trimmerExpectedVoltage = HEATERS_MAX_OPERATING_VOLTAGE_V * ( 1.0F - trimmerDC ); - BOOL isMainPriOut = ( fabs( mainPriExpectedVoltage - mainPriVoltage ) > HEATERS_VOLTAGE_TOLERANCE_V ? TRUE : FALSE ); - BOOL isSmallPriOut = ( fabs( smallPriExpectedVoltage - smallPriVoltage ) > HEATERS_VOLTAGE_TOLERANCE_V ? TRUE : FALSE ); - BOOL isTrimmerOut = ( fabs( trimmerExpectedVoltage - trimmerVoltage ) > HEATERS_VOLTAGE_TOLERANCE_V ? TRUE : FALSE ); + BOOL isMainPriOut = FALSE; + BOOL isSmallPriOut = FALSE; + BOOL isTrimmerOut = FALSE; +#ifndef _RELEASE_ + if ( HW_CONFIG_BETA == getHardwareConfigStatus() ) + { + // V3 use CPU based value for Primary, same as Secondary + mainPriVoltage = getMonitoredLineLevel( MONITORED_LINE_24V_GND_SMALL_PRIM_HTR_V ); + } + else +#endif + { + // TODO this is not working on DVT-002 + // If the system is DVT, check the FPGA persistent alarm of the main primary heater's voltage ADC + //checkFPGAPersistentAlarms( FPGA_PERS_ERROR_MAIN_PRIMARY_HEATER_VOLTAGE_ADC, getFPGAHeaterGateADCErrorCount(), getFPGAHeaterGateADCReadCount() ); + } + + isMainPriOut = ( fabs( mainPriExpectedVoltage - mainPriVoltage ) > HEATERS_VOLTAGE_TOLERANCE_V ? TRUE : FALSE ); + isSmallPriOut = ( fabs( smallPriExpectedVoltage - smallPriVoltage ) > HEATERS_VOLTAGE_TOLERANCE_V ? TRUE : FALSE ); + isTrimmerOut = ( fabs( trimmerExpectedVoltage - trimmerVoltage ) > HEATERS_VOLTAGE_TOLERANCE_V ? TRUE : FALSE ); + if ( getCurrentOperationMode() != DG_MODE_INIT ) { checkPersistentAlarm( ALARM_ID_DG_MAIN_PRIMARY_HEATER_VOLTAGE_OUT_OF_RANGE, isMainPriOut, mainPriDC, HEATERS_VOLTAGE_TOLERANCE_V ); checkPersistentAlarm( ALARM_ID_DG_SMALL_PRIMARY_HEATER_VOLTAGE_OUT_OF_RANGE, isSmallPriOut, smallPriDC, HEATERS_VOLTAGE_TOLERANCE_V ); checkPersistentAlarm( ALARM_ID_DG_TRIMMER_HEATER_VOLTAGE_OUT_OF_RANGE, isTrimmerOut, trimmerDC, HEATERS_VOLTAGE_TOLERANCE_V ); #ifndef _RELEASE_ - if ( SW_CONFIG_ENABLE_VALUE != getSoftwareConfigStatus( SW_CONFIG_ENABLE_V3_SYSTEM ) ) + if ( getHardwareConfigStatus() != HW_CONFIG_BETA ) #endif { // If the system is DVT, check the primary heater's power line voltage